1991 Volvo 240 141,000 miles automatic transmission California car.
1. In the process of removing the alternator to R&R the bushings, the wire from the engine harness got ripped out from the connection to the oil pressure switch which is on the engine block just in front of the oil filter. There is a bullet-type connector that attaches the wire to the switch. The old one is now destroyed. Where would I get another that will fit?
2. Is there a way to know whether or not the alternator bearing is failing? I ask because at one point in recent months I noticed that there was only one fan belt running the water pump and alternator. Normally there are two. A couple of months later, the remaining belt broke. It seems unusual for two belts to break in a relatively short period of time. I can only speculate that the first one broke while driving. The second one looked shredded and was still dangling there because when it broke, all belt movement stopped. These belts were installed about three years ago. I considered several possibilities.
- both belts failed due to getting oil soaked because of the oil leak. The first one likely failed and fell off while driving without being noticed.
- the alternator seized twice, causing the first belt to fail, then seized again later causing the second belt to fail
- both failed because the A/C and power steering belt pulleys were out of alignment due to worn accessory bushings . I had observed that the pulleys were not aligned.
- both failed due to excessive tightening of the belts by the mechanic who last changed the timing belt and seals.
Although the alternator seizing up seems unlikely, I want to be more certain before finishing up the oil leak repair while the engine front is taken apart. I've finished installing new bushings on the alternator and have observed on the work bench that it turns smoothly without any noise. At an interim point after removing the belts but prior to removing the alternator and before adjusting the tightness of the belt, I drove the car and observed the most awful tortured and loud sound . It did not sound like the customary belt squeal. It could be heard throughout the neighborhood, especially when accelerating. Squirting water on the belt helped just a little. That convinced me that there must be a bad bearing. However, and to my relief, all of that stopped when I tightened the belt to specifications. Is a smooth turning pulley sufficient to conclude that the bearing is not failing?
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